GAUS BATTERY CHARGER
GBC12-48V50A
High Frequency Intelligent Multi Step Charger
DESCRIPTION AND USER MANUAL
Belgrade, February 2006.
1. TABLE OF CONTENTS
1. TABLE OF CONTENTS .............................................................................................................................................................. 2
2. GAUS BATTERY CHARGER GBC48V50A ................................................................................................................................. 3
3. TECHNICAL SPECIFICATIONS ................................................................................................................................................ 4
4. LCD Display ................................................................................................................................................................................ 5
4.1. Setting mode ............................................................................................................................................................................................. 5
4.2. Main screen (display) ................................................................................................................................................................................ 5
4.3. The list of all the messages GBC48V50A is able to register while operating ........................................................................................... 6
5. INSTRUCTION FOR USE ........................................................................................................................................................... 8
5.1. Device installation ..................................................................................................................................................................................... 8
5.2. Starting charge .......................................................................................................................................................................................... 8
6. DEVICE SETTINGS ................................................................................................................................................................... 9
7. LEGEND OF MARKS (SIGNS) AND CONCEPTS ................................................................................................................... 12
Default settings for Gaus Battery Charger GBC48V50A ............................................................................................................................... 13
9. PRECAUTION MEASURES ...................................................................................................................................................... 14
GAUS StS-Belgrade, Jurija Gagarina 167/41, tel/fax: +381 11 22 79 142, mob. +381 63 215 722, serv. +381 25 421 095
www.gaus-sts.com, [email protected]
2
2. GAUS BATTERY CHARGER GBC12-48V50A
High Frequency Intelligent Multi Step Charger
GBC12-48V50A (GBC) is microprocessor device for charging and maintenance of industrial (traction)
lead-acid batteries with nominal voltage of 48V with maximum charge current of 50A. It is developed as a
consequence of need for small (light), easy for use, safe, reliable, and fully controllable and relatively cheep
device for servicing and maintenance of industrial batteries. GBC is one-phase high frequency half-bridge
constant voltage charger with current limit. That means that current reaches output voltage on connected
battery, which is limited. After reaching desired voltage, that voltage level is maintaining constant and charge
current drops as battery is charging. Multi step charging permits combining charge and pause periods with
different current values. A GBC Maintenance operation is ideal for “poofer” connection of charger, battery and
load (always keep battery in ready state, on constant voltage level with small current). GBC is made of three
charging modules controlled by main microprocessor. Modules are fitted in common alum-steel box with
central control unit, protection devices, and keyboard and display unit. Charge current (current limit) is selected
as function of nominal battery capacity or in function of desired charging time and capacity. Also, charging
voltage is settable as charging voltage per one cell (multiplies with 24 cells). Voltage, current, duration and
capacity (Ah) are controlled and many precaution measures are implemented.
As device is microprocessor, with measuring current, voltage, duration, Ah, temperature of heat sink of
semiconductor parts, it is possible to implement different algorithms. It is possible to change voltage and
current limits, conditioning of charge characteristic, pausing, waiting for event (measuring Ah during charge),
conditioning end of charging (duration, Ah...), connection with PC computer, analyse and printing charge
graphs etc.
Energy circuit is made of input filter with high quality electrolytic capacitors (EPCOS-SIEMENS
105C), high-frequency transformer (ETD Siemens) and mosfet half-bridge (International Rectifier IR), ultra
fast diodes, and inductance and PWM modulator. Working frequency is 30kHz.
Thanks to voltage limit, it is possible to charge without surveillance, because there is not over charge
(over night or during weekend). As well, in a case of main power failure during charge, after it’s returning
device automatically continues charging with parameters, which were previously set (before power failure).
LCD display with 2x16 characters shows values of current, voltage, time, capacity, device status, warnings,
alarms etc. There are more than 10 menus for setting the parameters of charging. Device is placed in red
plasticified alum-steel box. Main switch, start (scroll) and stop (select) buttons, switch R/S (Ready/Set), led
diodes, LCD display for indication and connector for communication with PC computer and indication lamps
are placed on the devices front panel. Charge cables, power supply cable and holders for cables, automatic
mono-phase fuse in output circuit and main fuse are on the back panel of device.
With software GCDTS v1.01 it is possible to connect device with PC computer via RS232 serial port.
Software gives opportunity of showing charge and discharge graphs in real time, possibility of reading charge
and discharge data in case that device wasn’t connected
with PC, printing and storing the results, creating reports
etc.
Gaus Battery Charger GBC48V50A has following
protections:
1. No sparks during connecting or disconnecting plugs
from battery in charge operation;
2. Forced temperature controlled air cooling;
3. Control of a minimum of allowed connected battery
voltage (forbidden start for voltages less than 20V);
4. Temperature
protection
on
heat-sink
of
semiconductor energy components;
5. In case of main power failure, after its restoring,
charging automatically continues with earlier set
parameters;
GAUS StS-Belgrade, Jurija Gagarina 167/41, tel/fax: +381 11 22 79 142, mob. +381 63 215 722, serv. +381 25 421 095
www.gaus-sts.com, [email protected]
3
6. Slow automatic fuse T25A in AC circuit;
7. Automatic slow fuse 63A in DC circuit;
8. Soft start of PWM modulator;
9. Soft start in charging input electrolytic capacitance;
10. Short circuit protection (if detected current is more than 60A charger is automatically turned off);
11. Over voltage protection (>72V);
12. Protection from plugs (cables) falling during charge (freezing device until solving of problem);
13. Reverse polarity protection with forbidden start.
3. TECHNICAL SPECIFICATIONS
-Type of voltage converter: mono-phase half-bridge high frequency DC-DC converter;
For charging lead-acid batteries, industrial and stationary, hermetic, GEL...
-Supply 230V +/- 10%, 50Hz 4kW; output power 3000W;
-Nominal input current:
18A; maximal start current: 20A
-Instruments: LCD display 2x16 characters, ampermeter 0-99.9A, voltmeter 0-99.99V, temp 1 –99ºC do 99ºC
-Cables with Pb (Ms) plugs: l=2m, S=16mm2
-Ambient temperature: 5 do +40ºC
Charge current
Battery type
Charging characteristics
Charge voltage range
Output voltage
Capacity
MAINTENANCE operation
MULTI STEP
Accuracy
Resolution
Current pulsation
Output voltage pulsation
Energy circuit
Frequency
Ŋ
Cooling
Control characteristic
Control variable
LCD display during charge
Display
Control elements
Housing
Dimension (WxDxH)
Weight
0-50A Cn/10, settable: 0-50A, step 1A
Lead-Acid 12V, 24V, 36V, 48V (4x12V); Cn from 33Ah to 500Ah, Sb-Sb, Sb-Ca, Ca-Ca,
AGM, Gel
IU, optionally IUa+ equalising, IU-Ia+ equalising, I-U1-U2
10-66V (permitted by software)
Settable: 2.20-2.75V/Cell step 0.1V
Default: 2.4V/Cell, 2.47V, 2.57, 2.67V/Cell
24V or 48V battery (12 or 24 cells in serial connection) from Cn=30Ah-500Ah
Constant voltage charge, 2.30V/Cell x 6 x No Batteries in serial connection
from 2 to 4 steps, constant current, PAUSE operation with I=0A
Better than 3%
100mA and 100mV
0,4A max
<200mV
MOSFET transistors, ultra fast diodes
30kHz
82%
Forced air
Constant voltage charger with current limit
Current, voltage, capacity Ah, time
Status, current, voltage, duration, Ah, warnings, alarms…
LCD display with 2x16 characters
Main switch, start and stop buttons, switch Ready/Set, LED diodes
Alum-Steel grey plasticified rack box RAL 3002 19” x 6HE x 400mm
420x400 (510)x280mm
25kg
GBC48V50A complies with the following requirements:
EN60335-1/194 (Safety of household and similar electrical appliances-Part 1: General requirements); SIST
EN 60335-1, May 1998; JUS IEC 60335-1 1998. and
 EN60335-2-29 (Part 2: Particular requirements for battery chargers); JUS IEC 60335-2-29 year 2000.
Options: Final version with charging parameters for specified battery, automatic start/stop operations, without
menus for setting parameters…

GAUS StS-Belgrade, Jurija Gagarina 167/41, tel/fax: +381 11 22 79 142, mob. +381 63 215 722, serv. +381 25 421 095
www.gaus-sts.com, [email protected]
4
4. LCD Display
4.1. Setting mode
Setting mode can be entered only while the device is in READY mode (charge process has not been
started). By turning R/S switch on the device turns into a setting mode and yellow led diode is on. In this mode
buttons STOP and START take new meanings such as SCROLL and SELECT respectively. Navigation
through menus is done by SCROLL button, by pressing SELECT one can enter submenu. If there are not submenus, than SCROLL acts like an increment of specific numeric values, and SELECT is used to confirm the set
value. It is possible to reach desired specific value even faster by constant pressure onto SCROLL button. At
any point it is possible to turn setting mode off and return to READY mode by simple click onto R/S switch
when yellow LED diode turns off and the green turns on. All the previous done setting has been saved.
4.2. Main screen (display)
The example of enlarged main screen:
C H R
0 4 : 3
9 0
1 :
.
4
4 A
9 !
h
3
5
1
9
0
.
.
2 V
0 A
The first three characters in the first line of LCD display show the condition of device and they can be:
CHR -marks charge operation,
FIN -marks finished operation,
PA
-marks the condition of pause during alarm,
RDY -marks ready condition after reset or at turning on the device.
MAI -marks battery maintenance operation after charging (poofer connection)
The following 7 characters are reserved for capacity display. Second line begins with a clock (altogether 8
characters for hours, minutes and seconds during charge process and 7 characters for minutes, seconds and
tenths during discharge process).
Ninth character of second line (such as exclamation mark) can be:
SPACE
-marks process with factory values,
!
-Marks process with user defined values,
3
-marks current step in multi step charging
Second line finishes with current info. Blinking the alarm message on the main screen shows alarm conditions.
GAUS StS-Belgrade, Jurija Gagarina 167/41, tel/fax: +381 11 22 79 142, mob. +381 63 215 722, serv. +381 25 421 095
www.gaus-sts.com, [email protected]
5
4.3. The list of all the messages GBC48V50A is able to register while operating
G a
u
s B a t
G B C 4
t . C h a r
8 V 5 0 A
g
e
r
It shows while turning the switch on if the device is plugged (Power ON).
P O W E R
p r o c e
s
F A I L U R E !
c o n t i n u
e
d
Right after turning the device it’s been checked whether it had turned off by pressing OFF button or by power
failure during charge process. If GBC detects this situation the previous charge process continues automatically
with parameters as were set before.
C
t
h a r
i m e
g
r
e
c
s t
o u
o
n
p
t
e
e
d
r
o
n
If the user sets a new value to Charge Duration, after that charge process will be stopped (if it hasn’t been
stopped for other condition or manually). Maintenance operation will automatically replace charge
operation except in the case that user disabled maintenance operation in SET menu before he started
charging*.
C h
D e
a
f
r
a
g
u
e
l
t
s t
t
o p e
i m e
d
r
o
n
If the user did not set new value to Charge Duration it would have a factory set value (96 hours). After that time
charge process will be stopped* (if it had not been stopped earlier under any other condition or even manually).
C h
R e
a
a
r
c
g
h
e
e
d
s t
c
o
a
p
p
e
a
d
c
i
o
t
n
y
If the user set Capacity Limit (it had not been set in the factory), charge process would be stopped when the
battery gets a certain amount of Ah. e.g. Capacity Limit = 200 Ah will stop charge* when the battery get
200Ah.
C h
U s
a
e
r
r
g
e
s t
o
p
e
d
b
y
This message appears when the user manually stops charge process by pressing STOP button.
V o
V o
l
l
t
t
a
a
g
g
e
e
a
l
>
a
r m !
7
2 V
GAUS StS-Belgrade, Jurija Gagarina 167/41, tel/fax: +381 11 22 79 142, mob. +381 63 215 722, serv. +381 25 421 095
www.gaus-sts.com, [email protected]
6
Alarm, when a higher voltage battery has been connected. Charge start is not possible! Also, if that situation
happens during charging, GBC will stop.
A l
C h
a
e
r m
c k
N o
c a
b
b
l
a t t
e & f
e
u
r
s
y
e
Alarm caused by a load disconnection, automatic fuse fail, and low battery voltage or cable disconnection. By
turning the alarm off charge will automatically be continued.
U s e r
P R E S
S
S
e t t
i n g
S T A R T
s
!
If charge process was started by user setting (not ones set by factory), this warning would inform him and
would give him an opportunity to give up.
T
h
e m p
e a t
e
s
r
i
a
n
t .
k
t
a
.
l
a
>
r m
8 0 C
If the temperature of transistor heat sink is over 80C charge process will automatically be stopped. Start is not
possible at this stage. The charge process will automatically be continued when the temperature falls under 50C
unless the user resets the device earlier.
T e m p
A m b i
e
e
r
n
a
t
t .
t
.
a
<
l
a
r m
5 C
Ambient temperature is too low. Start is not possible. If charge were on it would be stopped until temperature
exceeds 5C. Then it automatically continues unless the user hasn’t manually reset GBC.
C h
h i
a
g
r
h
g
e
c
u
S t
r r
o
e
p
n
e
t
d
b
y
b
y
If current larger than 60A appear during charging, GBC will stop.
C h a r
l o w
g
c
e
u
r
S t
r e
o
n
p
t
e
d
If charging current drops below 0.175A, GBC stops*.
GAUS StS-Belgrade, Jurija Gagarina 167/41, tel/fax: +381 11 22 79 142, mob. +381 63 215 722, serv. +381 25 421 095
www.gaus-sts.com, [email protected]
7
5. INSTRUCTION FOR USE
5.1. Device installation
1.
Turn the power supply socket on;
2.
Turn POWER switch on;
3.
An intro message will appear on LCD display and will be on for 3 seconds. After this message the
device will automatically continue charging process if it has already been on, or off by power fail or by a
violent switching off. In that case another message, from the previous list, will be shown, charging process will
be either continued or finished by pressing STOP button. If R/S switch is in READY position (green READY
LED diode is on) MAIN SCREEN will be shown on LCD display and it is possible to read current battery
voltage. If R/S switch is in SET mode (yellow LED diode is on), it should be turned into READY mode. At this
level some settings could be made (that will be explained in the following text);
4.
Connect charger loads onto the battery in a right way. Red load connects onto plus pole, and the black
one onto a minus pole of the battery. PLEASE NOTE! Poles on the battery should be cleaned and a load
properly fixed. Should be kept in mind to choose a connection for charge;
5.
By pressing START button the device will ask you to select charging parameters such as charging
voltage per cell (and complete battery) for constant voltage charging and current limit (see description
below). Selection is made by SCROLL button (STOP button), and the set value is being confirmed by
pressing SELECT (START button) once again, which starts charging process;
6.
It is possible to follow charging process on LCD display (time that passed, charge current, charge
voltage, inserted Ah capacity, the process status and eventually appeared irregular states caused by load
disconnecting, warming-up etc.);
7.
It is possible to stop the charging process at any time by pressing STOP button.
5.2. Starting charge
Pressing the button START in Ready State of device starts phase of setting charge parameters.
User Settings Press Start – this massage means that some settings which are different than default one are
done by user in SET menu (symbol ! marks during charging that some parameters are set by user). Press Start
button once again and select value of constant charge voltage and current limit.
Press on START/SELECT:
C e
2 .
l
4
l
V o l t
7 V x 6 x
.
4 =
L
i m
5 9
i
.
t
2
With button STOP/SCROLL choose voltage limit:
Charge U/Cell:
2.47, 2.57, 2.67, 2.20....2.75 with step of 0.01V/Cell.
NOTICE: Voltage limit is very important for battery, which is charging and should be selected according
battery manufacture’s instructions.
Following description is not valid for multi step charging.
Pressing on SELECT confirm selected value for charging voltage and opens window for setting charge current
first with 10A step and after that with 1A step.
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8
I
S
s
e
e
l
l
e
1
c t
0 A
S
e
l e c
1 A
t
s
C
s t
u
e
r
p
r
:
e
n
2
t
0 A
C
t e
u
p
r
r
I
e
=
n
2
t
5 A
Pressing on SELECT confirm selected value for charging current and opens window for confirming charge
parameters.
U 2
C o
.
n
4
t
7 V / C
i n u e ?
I :
2 5 A
Y e s
SCROLL changes Yes to No and vice verso. Press on SELECT starts charging (Yes) or cancel complete
parameters setting procedure ( No).
Pressing STOP button at any time can stop charge.
In case of multi step charge, menu for setting current is skipped because current for each step is already set in
SET menu during multi step settings. Continue massage is:
U 2
C o
.
n
7
t
5 V / C
i n u e ?
1
5
5 A h
Y e s
Display indicates amount of Ah according to chosen current and duration for each charging step in SET menu.
6. DEVICE SETTINGS
6.1. USER SETTINGS
Changing the switch READY/SET into SET position (yellow led diode turns on) enters the SET menu.
Press on SCROLL opens the first menu:
Default settings –for restoring original setting of charger.
- D e
f
a
- m e
u l t
n u
s
v
e
1
t
t
i
n
a
l
u
e
s
g
S
Press on SELECT:
D e
r e
f
s
a
t
u
o
l
r
t
e
d
Press on SCROLL:
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Charge Condition – Group of charging conditions.
- C h
a
r
- m e n u
g e
C o
n
2
d
i
t
.
>
>
Press on SELECT:
Time Condition – Charging should be stopped after user defined time period (default – 96h).
Press on SCROLL:
T
- - i m e
- m e n u
C o n d
i
2
t
a
i
o
n
>
>
f
t
e
r
- m i
n
Press on SELECT:
-
9
6
S T O P
H r s
a
:
By combining buttons SCROLL and SELECT it is possible to set up charge duration from 15 min to 96h (steps
1h and 15 min).
-
4
0
S T O P
H r s
a
:
f
t
3
e
0
r
:
5 7
5
- m i
n
During start procedure display appears as:
T
I
:
s
4
e
0
l
h 3 0 m C
1 A s t e
:
p
9 A h
. 5 A
After selecting charge duration, user can set up amount of Ah in charge process:
Capacity Condition.
- C a
p
a
- m e
c i t
n u
y
2
C o
b
n
d
.
>
>
e
e
r
d
-
-
-
Press on SELECT opens capacity condition menu:
-
-
0
S T O P
a
A h
L o
f
a
t
d
Amount of Ah in charge process is choosing by combining SCROLL and SELECT buttons.
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www.gaus-sts.com, [email protected]
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Following menu is for choosing maintenance operation which will (or not) automatically start after finishing
regular charging (for poofer connection, keeping battery always ready).
- - m a i
n
- m e
t e n
n u
a n
2
e
c
d
-
-
>
>
t
?
e
r y
Y e
s
Press on SELECT opens menu with YES/NO options.
I n
m a
c
i
l
n
u d
t e
e
n
B a
a n c
t
e
After confirming selection, SCROLL button opens submenu, which permit return to menu 2.
<
<
-
- - m e
B a c k
n u
2
e
-
-
-
-
Press on SCROLL in root shows menu 3 for selecting number of batteries for charging in serial connection.
S
e
l
.
- m e
N o .
n u
B a
3
t
t
e
r
i
e
s
o
f
4
In this menu it is possible to select No 12V batteries from 1 to 4.
S
1
e l e
2 V
c t
B a
t
N u m b
t e r i
e
e
r
s
:
By pressing SCROLL in root, Multi-step menu appears.
M
u
l
t
- m e
i S t
n u
e p
P
4
r
o
g
.
>
>
Press on SELECT, opens menu with question for enabling multi step charging.
D e
P r
f
o
i
g
n
r
e
a
M
m
u l
:
t
i
S
t
e p
Y e
s
In case of enabling multi step, next step is to define number of charging steps (from 2 to 4).
D e
P r
f
o
i
g
n
r
e
N u m b
a m
S t e
e
p
r
s
o
:
f
4
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www.gaus-sts.com, [email protected]
11
After that, it is necessary to define current and duration for each step.
I
I
&
:
d T
3 .
0 A
s t e p
d T :
:
1
0
.
5
3
h
For each step (in this example the third one) current should be chosen from 0A to 50A with 1A step and
duration from 0 to 24h with 0,5h step. Selecting step current as 0A means operation of Pausing (step or period
of time without current). If duration for step is chosen as 0, that step will be ignored.
Also, with SCROLL in root, it is possible to open menu with information about number of power failure
situations during last charge process.
Power Fail last process
- L a
s
P
t
o w e
p r
r
o
c
F
e
a
s
i
s
l
:
-
-
0
Notice: All settings in SET option menus, remains in device memory only until its shut off. Original setting is
restored on next turn on. Warning USER SETTINGS follows starting charging with parameters different than
original ones!
7. LEGEND OF MARKS (SIGNS) AND CONCEPTS
A-(Amper) current unit
V- (Volt) voltage unit
Capacity Ah – battery capacity unit
Charge (CHR)– Charge
Maintenance (MAI)– Maintenance operation
Set – Setting of parameters
Ready (RDY)– Ready for work (start)
Start – Starting process
Stop – Stopping process
Current – value of DC current
Buzzer – part for sound beeping
LCD Display – Display with 2x16 characters
Password – for skilled users
Voltage limit – value of charging voltage on which some action has to be done
Power failure – Main power supply failure
Finish (FIN) – Finishing operation
Pause (PA) – Freezing operation
Alarm voltage limit – unacceptable voltage level
Alarm current – unacceptable current level
Time Condition – time condition for charge ending
Capacity Condition – capacity condition for charge ending
GAUS StS-Belgrade, Jurija Gagarina 167/41, tel/fax: +381 11 22 79 142, mob. +381 63 215 722, serv. +381 25 421 095
www.gaus-sts.com, [email protected]
12
Default settings for Gaus Battery Charger GBC48V50A
Parameter
Charge Voltage/Cell
Alarm Low Voltage
Range
2.20V/Cell – 2.75V/Cell
settable by user from START menu with
0.01V/Cell step
2-4
settable by user from SET menu
0A-50A, settable by user from START
menu with 1A step
-
Alarm High Voltage
-
Alarm Current
-
Minimum Current
(Current stop)
-
Capacity Condition
0-405Ah
0Ah means that capacity condition
should be ignored , settable by user from
SET menu with 5Ah step
1min-96h 45min
96h:00min
settable by user from SET menu, 15min
step
Yes/No
Yes
choosing by user from SET menu
Number of 12V Batteries
in serial connection
Charge Current
Time Condition
Maintenance (poofer
connection) only for 48V
batteries*
Charging parameters in
maintenance operation
only for 48 batteries
MultiStep
NoSteps in MultiStep
Charging with constant voltage at 55.2V
current limit is the same one which was
chosen through START menu by user
No/Yes choosing from SET menu
2-4, settable from SET menu
Default
2.47V/Cellx6x4= 59.2V
internally set
4 (48V)
internally set
20A
internally set
10V
internally set
72V
internally set
60A
internally set
0.175A
0A if Iselect=0A PAUSE
internally set
not defined, 0Ah
No
2
*If Maintenance operation is included in charging process, that means that after regular charging with chosen
voltage and current limit, charger will automatically continue with charging the battery with constant voltage of
55.2V (poofer connection). In that case, charging can be stop only manually by pressing STOP taster. In case of
power failure, charger continues after its restoring.
Also, time and capacity conditions, default timer condition are ignored in maintenance operation.
If user use multi step charging, maintenance operation will follow charging in steps, unless user in SET menu
disables that operation before starting charge process.
GAUS StS-Belgrade, Jurija Gagarina 167/41, tel/fax: +381 11 22 79 142, mob. +381 63 215 722, serv. +381 25 421 095
www.gaus-sts.com, [email protected]
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9. PRECAUTION MEASURES
1. Please read the instruction for use and warnings;
2. To avoid electric shock, disconnect the cable and test cables from the battery before taking
the device cover off or before safety fuse change;
3. WARNING! Gases realised during charge process are explosive. Do not smoke, avoid fire
and sparkles;
4. Do not expose device to direct sun light, extreme temperature or moisture;
5. Device must be earth grounded;
6. Do not connect device to battery with nominal voltage larger than 48V. Connected battery
voltage must be ranged 10 to 66 volts;
7. Do not connect the device on a battery that is in a vehicle. Charged or tested battery should
be outside any vehicle;
8. Always take into consideration the correct polarity while connecting the battery. Red cable
onto plus, black onto minus battery pole. Inversion polarity is situation in which it is not
possible to start charging;
9. Place the device to enable right flow of dissipated heat (do not cover ventilation holes). Use
the device only in a well ventilated areas. Avoid intensive warming and battery «boiling»
during charge;
10. Keep the device away from children;
11. Only skilled and qualified person can service the device.
GAUS StS-Belgrade, Jurija Gagarina 167/41, tel/fax: +381 11 22 79 142, mob. +381 63 215 722, serv. +381 25 421 095
www.gaus-sts.com, [email protected]
14